Mouthguard system for protecting soft tissue

ABSTRACT

A mouthguard system can be configured to provide protection to the soft tissues surrounding the mouth. A mouthguard system can include a front lip protection portion, a teeth engagement portion connected to and positioned posterior to the front lip protection portion, and a channel defined within a base layer of the teeth engagement portion. A bite layer is disposed within the channel having a durometer less than other portions of the mouthguard system. The mouthguard optionally includes one or more breathing channels and one or more flavorants.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to Provisional Application No. 61/784289, filed Mar. 14, 2013 and entitled, “MOUTHGUARD WITH COMPRESSION CHANNEL,” the contents of which are herein incorporated by reference in their entirety.

BACKGROUND

Mouthguards are typically used to protect the teeth, oral tissue and gums from impact and abrasion. Mouthguards can reduce the chance of shock and other injuries resulting from high impact collisions and blows during athletic competition. Different types of mouthguards are available including non-personalized, universal, and stock model type, as well as those that are custom formed to the teeth of an individual user.

SUMMARY

Aspects of various embodiments pertain to a mouthguard that is configured to provide protection to the soft tissues surrounding the mouth. A mouthguard includes a front lip protection portion, a teeth engagement portion connected to and positioned posterior to the front lip protection portion including a base layer and defining a channel formed within the teeth engagement portion. A bite layer is disposed within the channel having a durometer lower than the durometer of the teeth engagement portion. The mouthguard optionally includes one or more breathing channels and one or more flavorants.

While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a partial elevational view showing the jaws and mouth of a user wearing a mouthguard, according to some embodiments.

FIG. 2 is a rear perspective view of a mouthguard, according to some embodiments.

FIG. 3 is a front view of the mouthguard of FIG. 2, according to some embodiments.

FIG. 4 is a cross-sectional view taken along line A-A of FIG. 1, according to some embodiments.

FIG. 5 is a cross-sectional view taken along line B-B of FIG. 1, according to some embodiments.

While the invention is amenable to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are described in detail below. The intention, however, is not to limit the invention to the particular embodiments described. On the contrary, the invention is intended to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

The following detailed description refers to the accompanying drawings which show specific embodiments. Although specific embodiments are shown and described, it is to be understood that additional or alternative features are employed in other embodiments. The following detailed description is not to be taken in a limiting sense, and the scope of the claimed invention is defined by the appended claims and their equivalents.

FIG. 1 illustrates the environment in which a mouthguard 110, shown schematically, is used. A mouthguard user has a mouth 10, generally including a rigid upper jaw 12 and a movable lower jaw 42 which are movably coupled at a temporomandibular joint (TMJ). The rigid upper jaw 12 has gum tissue 14 within mouth 10. Gum tissue 14, as well as the bone thereunder, support anterior teeth (incisors and canines) 18 which have incisal or biting surfaces. The gum tissue 14 and the bone thereunder also support posterior teeth (molars and bicuspids) 22 which have cusps and biting surfaces 26. The movable lower jaw 42 supports a bone covered by gum tissue 44 which further supports anterior teeth (incisors and canines) 46 and posterior teeth (molars and bicuspids) 48 with occlusal surfaces 49. Soft tissue anterior to rigid jaws 12 and 42, such as upper and lower lips (not shown), are attached to and often cover the gum tissues 14, 44 and a portion of the anterior teeth 18, 48.

FIGS. 2 and 3 show the mouthguard 110, according to some embodiments. FIG. 2 is a rear perspective view of the mouthguard 110, the mouthguard including a front lip protection portion 112 and a teeth engagement portion 114. FIG. 3 is a front view of the mouthguard 110 showing the front lip protection portion 112.

The front lip protection portion 112 has various possible heights and sizes, and it is relatively large to help provide additional protection to the soft tissues surrounding the mouth. For example, the front lip protection portion 112 is configured or otherwise sized and shaped to entirely cover a lip or both lips of the wearer. In some embodiments, the front lip protection portion 112 includes an interior surface 114 facing toward the teeth of the user and an exterior surface 146 facing away from the teeth of the user. In some embodiments, the front lip protection portion 112 includes an upper lip protection segment 140, also described as an upper lip section or portion, and a lower lip protection segment 142, also described as a lower lip section or portion. Although as shown the front lip protection portion 112 includes both protection segments 140 and 142, in other embodiments the front lip protection portion 112 includes one of the protection segments 140 or 142. The upper lip protection segment 140 is configured to protect the upper lip of the mouth 10 from impact. Often, a sharp impact to the lip will cause a laceration of the lip. In a similar way, the lower lip protection segment 142 is configured to protect the lower lip of the mouth 10.

In some embodiments, as shown, the front lip protection portion 112 includes one or more breathing channels 116 that extend through the front lip protection portion 112 in order to help the user to breathe easily, even when the user's teeth are clenching down on the mouthguard 110 or when the user's lips form a seal with the mouthguard 110, for example. In some embodiments, each breathing channel 116 is formed in an opening of the exterior surface 146 of the front lip protection portion 112. As shown, a breathing channel 116 opens in an area of the exterior surface 146 between, or at the joining of, the upper lip protection segment 140 and lower lip protection segment 142. In some embodiments, a breathing channel 116 opens in an area of the exterior surface 146 in at least one of the upper lip protection segment 140 and lower lip protection segment 142.

In some embodiments, the teeth engagement portion 114 is posterior to the front lip protection portion 112 at the anterior of the mouthguard 110. In some embodiments, the teeth engagement portion 114 includes a base layer 117 defining a channel 118 and a bite layer 120 that is disposed in the channel 118 of the base layer 117. In some embodiments, the channel 118 is at least partially defined by an outer wall 122 and an inner wall 124. In some embodiments, the anterior of the mouthguard 110 has a greater overall height than the posterior of the mouthguard. For example, the overall height of the front lip protection portion 112 exceeds the overall height of either the outer wall 122 or the inner wall 124.

In some embodiments, the one or more breathing channels 116 extend from the inner wall 124 to the exterior surface 146 of the front lip protection portion 112. Each breathing channel 116 has an anterior opening and a posterior opening and extends through the front lip protection portion to the teeth engagement portion. In some embodiments having two breathing channels 116, a first breathing channel is positioned on a side of a tongue of the user opposite a second breathing channel. In some embodiments, the mouthguard 110 can be configured to include a tether (not shown), which can be used by the user to attach the mouthguard 110 to a helmet. The tether can be permanently attached, or the tether can be removably attached, to tether attachment structure 138 (FIG. 3) and insertable by the user.

FIG. 4 is a cross-sectional view taken along line A-A of FIG. 2, and FIG. 5 is a cross-sectional view taken along line B-B of FIG. 2. As illustrated in FIG. 4, in some embodiments, the channel 118 can include a floor 126. For example, the bite layer 120 is disposed over the floor 126, between the outer wall 122 and the inner wall 124. In some embodiments, portions of the bite layer 120 vary in thickness at different locations about the channel 118. In some embodiments, as illustrated, the floor 126 includes one or more apertures 128. If the apertures 128 are present, the bite layer 120 optionally extends downwardly into the one or more apertures 128. This can help with securing the bite layer 120 in place within the channel 118. In some embodiments, the floor 126 can include one or more through holes 130 that permit the bite layer 120 (e.g. bite pad) to extend all the way through the teeth engagement portion 114. As a result, forces applied to the upper molars can be transmitted through to the lower molars to better absorb impacts.

In some embodiments, the front lip protection portion 112 and the teeth engagement portion 114 are generally formed of a first material with the bite layer 120 of the teeth engagement portion 114 being formed of a second material that is different from material forming the remainder of the front lip protection portion 112 and the teeth engagement portion 114. For example, the base layer 117 is optionally formed of the first material and the bite layer 120 of the second material. In some embodiments, the bite layer 120 exhibits a lower durometer than the base layer 117 of the teeth engagement portion 114. For example, the first material and the second material are optionally the same polymer or different polymers having different durometer values. For example, the first material can be a low density thermoplastic rubber having a first durometer and the second material can be a low density thermoplastic rubber having a second durometer that is less than the first durometer. Examples of a first material include a thermoplastic rubber having a Shore A durometer of about 62. Examples of a second material include a thermoplastic rubber having a Shore A durometer of about 52 or less. In some embodiments, a ratio of the second durometer to the first durometer (i.e., a value of the second durometer divided by a value of the first durometer) is about 90% or less is about 85% or less or is between 80% and 90%.

In some embodiments, the first material is a composite of a copolymer of ethylene and vinyl acetate (EVA), such as the Elvax™ resins commercially available from Ashland Chemical Company, and an elastomeric material such as thermoplastic rubber or vulcanized rubber. In some embodiments, the first material includes about 50 percent to about 80 percent by weight of the elastomeric material and about 20 percent to about 50 percent by weight of the copolymer of EVA. In some embodiments, the EVA copolymer can include vinyl acetate in the range of about 18 percent to about 28 percent by weight.

In various embodiments, the bite layer 120 is formed of a second material that is 100 percent of a copolymer of ethylene and vinyl acetate, and has at least 33 percent of vinyl acetate by weight. In various embodiments, the second material includes a copolymer of ethylene and vinyl acetate, and has at least 40 percent of vinyl acetate by weight. For example, a suitable second material is a soft EVA 40. Alternatively, another suitable second material includes EVA 100.

An illustrative but non-limiting example of a suitable first material is thermoplastic rubber marketed under the trademark KRATON™, which is marketed by GLS Plastics of 740B Industrial Drive, Cary, Ill. 60013. This thermoplastic rubber is unique in that it is injection moldable, FDA approved, and readily adheres with copolymers of EVA. Furthermore, the thermoplastic rubber has a melting or softening point significantly higher than that of EVA.

In some embodiments, the mouthguard 110 is a boil and bite mouthguard. For example, the bite layer 120 is formed of a second material that softens at a temperature in the range of about 100 to about 150 degrees Fahrenheit, while the rest of the mouthguard 110 is formed of a first material that softens at a temperature that is in the range of about 140 to about 200 degrees Fahrenheit.

Before the mouthguard 110 can be used, for example, a user must fit the mouthguard 110 in their mouth. To do this, the mouthguard 110 is momentarily submersed into boiling water for 16-60 seconds. This will cause the bite layer 120 to soften without appreciably softening the rest of the mouthguard 110. Thereafter, the mouthguard 110 is immediately placed onto the user's teeth. The user bites down firmly and applies suction between the upper jaw and the mouthguard 110 while packing the mouthguard 110 with the hands along the cheeks and gums adjacent the anterior and posterior teeth of the upper jaw. The posterior teeth of the lower jaw will properly index upon the bottom surface of the mouthguard 110.

In some embodiments, the second material is a suitably soft thermoplastic rubber having a durometer low enough so that the mouthguard 110 does not have to be molded to the user's teeth. Rather, the bite layer 120 is sufficiently soft such that the bite layer 120 can accommodate and protect the user's teeth without a molding step. In other embodiments, the second material is suitably conformable, or soft, to facilitate use without fitting or molding to the user's teeth (e.g., as previously described), but should the user wish to do so, the mouthguard 110 is also configured to permit fitting or molding (e.g., using boil and bite methods such as those previously described).

In some embodiments, the mouthguard 110 further includes one or more flavorants dispersed within the first material, the second material, or both materials. In some embodiments, at least one of the one or more flavorants can include a sweetener. In some embodiments, individual flavorants are in different polymeric materials, with the polymeric materials defining different mouthguard layers as desired. In some embodiments, at least one of the polymeric materials can include two or more distinct flavorants, with one of the flavorants being a sweetener. In some embodiments, at least one of the polymeric materials can be free of flavorants.

Flavors are generally defined as the sensory impression provided to the person detecting the flavor. The flavor detected by an individual can be a combination of taste and smell. Examples of tastes include sweet, sour, bitter, salty, and other basic tastes. Smells are limitless. Flavorants are substances that provide a flavor or alter the detected flavor. Flavorants can be natural or synthetic. Salts are flavorants that enhance a salty taste. Sugars and other sweeteners are flavorants that enhance a sweet taste.

Illustrative but non-limiting examples of flavors that can be used in the flavored mouthguards described herein include a sweet flavor, a tart flavor, a salty flavor, a citrus flavor such as orange or lemon, a berry flavor such as strawberry, a mint flavor such as peppermint, spearmint, and the like. Other flavorants include cinnamon. It will be appreciated that flavorants can be combined in order to provide additional taste combinations. Two or more flavorants can be combined into a single polymer layer, or the flavorants can be separated, one in each polymer layer. In some embodiments, flavorants are disposed in separate layers to be deployed in targeted areas of the mouth. For example, a flavorant that is sweet, such as sucralose, is optionally deployed in layer toward a front region of the mouth while a different type of flavorant, such as a citrus flavorant, is optionally deployed in a layer toward a back region of the mouth.

A variety of flavorants can be used, including GRAS (generally regarded as safe) natural and artificial flavorants. In some embodiments, particular flavorants can be selected not only to provide a desired flavor or aroma, but also to accommodate the thermal processing parameters involved in molding a particular polymer. Some flavorants are disposed within water soluble carriers or oil soluble carriers. It will be appreciated that in some instances, a flavorant in an oil soluble carrier may have an increased affinity for the polymer to which the flavorant is added.

In some embodiments, the flavorants include one or more flavorants that can provide a sweet taste, or sweetness. A variety of different sweeteners can be used, including GRAS natural and artificial sweeteners. The sweetness-providing flavorants can be selected not only to provide a desired sweetness, but also in accordance with the thermal processing parameters of the polymer to which the sweetener is to be added.

Illustrative but non-limiting examples of suitable sweeteners include sugar alcohols such as sorbitol, maltitol, xylitol, mannitol, erythritol, and lactitol. Additional suitable sweeteners include saccharin, sucralose, and extracts from the Stevia plant. The sweetener can be added in any desired concentration, and can be added to the polymer in any suitable form, such as a liquid or a powder that can be mixed into a liquid polymer prior to molding. In some embodiments, the sweetener can be added at a concentration of about 0.5 to about 20 weight percent of the polymer. It will be appreciated that the desired concentration level can vary, depending on the particular sweetener being used, the desired taste effect and the specific polymer to which the sweetener is being added.

The flavorant can be added in any desired concentration. In some embodiments, flavorants providing tastes other than sweet can be added at a concentration of about 3 to about 30 weight percent of the polymer. In some embodiments, flavorants providing sweetness can be added at a concentration of about 0.5 to about 20 weight percent of the polymer. It will be appreciated that the desired concentration level can vary, depending on the particular flavorant being used, the desired taste effect and the specific polymer the flavorant is being added to. In some embodiments, the flavorant can be added to the polymer when making a master batch pellet that can subsequently be used when molding the mouthguard 110.

In some embodiments, the flavorants such as flavor oils or powders, can be mixed into a container of pellets that do not already include any flavorants. As a result of mixing, the pellets become coated with the flavorants and at least some of the flavorants can absorb into the pellets. The pellets are added to the injection molding machine in which friction and pressure melts and blends the material as it flows through the injection molding machine.

It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. For example, it is contemplated that features described in association with one embodiment are optionally employed in addition or as an alternative to features described in associate with another embodiment. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. 

We claim:
 1. A mouthguard system comprising: a front lip protection portion; a teeth engagement portion connected to and positioned posterior to the front lip protection portion, the teeth engagement portion including a base layer formed of a first material having a first durometer and defining a channel; and a bite layer formed of a second material having a second durometer that is lower than the first durometer, the bite layer being disposed within the channel.
 2. The mouthguard of claim 1, wherein the front lip protection portion and the teeth engagement portion are formed of the first material.
 3. The mouthguard of claim 1, wherein a value of the second durometer divided by a value of the first durometer is about 85% or less.
 4. The mouthguard of claim 1, wherein the second material and the first material are both low density thermoplastic rubber.
 5. The mouthguard of claim 1, wherein the first material includes an injection moldable thermoplastic rubber.
 6. The mouthguard of claim 1, wherein the first material includes a composite of a copolymer of ethylene and vinyl acetate and a rubber.
 7. The mouthguard of claim 1, wherein the second material includes a copolymer of ethylene and vinyl acetate having at least about 33 weight percent vinyl acetate within the copolymer.
 8. The mouthguard of claim 1, wherein the second material is selected having a durometer sufficiently low to accommodate and protect a user's teeth without a previous molding step.
 9. The mouthguard of claim 1, wherein the first material includes a flavorant.
 10. The mouthguard of claim 9, wherein the first material includes a flavorant that provides sweetness.
 11. The mouthguard of claim 1, wherein the first material includes at least two flavorants, with one of the flavorants providing sweetness.
 12. The mouthguard of claim 1, wherein the second material includes a flavorant.
 13. The mouthguard of claim 12, wherein the second material includes a flavorant that provides sweetness.
 14. The mouthguard of claim 12, wherein the second material includes at least two flavorants, with one of the flavorants providing sweetness.
 15. A mouthguard system comprising: a front lip protection portion, having a first overall height, and including at least one segment selected from an upper lip protection segment and a lower lip protection segment; a teeth engagement portion including a base layer having a first durometer and a bite layer having a second durometer that is less than the first durometer, the teeth engagement portion having a second overall height less than the first overall height and being connected to and positioned posterior to the front lip protection portion; a first breathing channel having an anterior opening and a posterior opening and extending from the front lip protection portion to the teeth engagement portion.
 16. The mouthguard of claim 15, wherein the base layer defines a channel within the teeth engagement portion and the bite layer is disposed within the channel.
 17. The mouthguard of claim 15, further comprising a second breathing channel having an anterior opening and a posterior opening and extending from the front lip protection portion to the teeth engagement portion.
 18. The mouthguard of claim 15, wherein the posterior openings of the breathing channels are positioned to correspond to opposite sides of a tongue of the user.
 19. The mouthguard of 15, wherein the at least one segment is sized and shaped to fully cover a lip of a user.
 20. The mouthguard of claim 15, wherein at least one of the first and second materials includes a flavorant. 